KR0167040B1 - Concrete complex materials and production thereof - Google Patents

Abstract

The present invention obtains a lightweight concrete composite having excellent mechanical strength.

Concrete composite material of the present invention is a part of the fusion between the chemical fibers, such as polyester, acrylic, polypropylene fused by filling the base material such as cement, gypsum, coal, etc. Harden.

Description

Concrete composite material and manufacturing method

The present invention relates to a concrete composite material suitable for use as a flooring material or a wall material for construction and a method of manufacturing the same.

As a concrete composite material, iron materials such as reinforcing bars and steel frames are used as base materials, and cement is used as a base material, but it is difficult to reduce weight and is inconvenient to handle. Therefore, lightweight concrete composites are used or proposed instead of using such steel.

As an example of such a lightweight concrete composite material, glass fiber is mixed with the cement of the base metal, vegetable fiber is mixed (see Japanese Patent Application Laid-Open No. 52-150431), and a cellulose fiber treated with flame resistance is used. Mixtures (see Japanese Patent Application Laid-Open No. 51-127526). However, these concrete composites are only a mixture of fibers as a reinforcing material in the base material, so the mutual entanglement between the fibers is weak, there is a problem that the tensile strength as a concrete composite material is not enough yet.

As another example, vegetable fibers are brought into contact with each other in the longitudinal and transverse directions, and impregnated with cement slurry is also proposed (see Japanese Patent Application Laid-Open No. 52-150431, supra). However, since this is only the overlap of the fibers, the inter-entanglement between the fibers is weak, and it also leaves a problem in terms of strength.

As the flooring material and wall material for building, there is no need for heat resistance to the extent that steel or glass fiber is used as a reinforcing material, but a lightweight concrete composite material having excellent mechanical strength such as tensile strength and the like is required.

An object of the present invention is to provide a lightweight concrete composite having excellent mechanical strength.

Hereinafter, the present invention will be described in more detail.

Concrete composite material of the present invention is a felt core material fused to a part of the chemical fibers entangled with each other in three dimensions, and cement, gypsum, coal or two of these costumes are filled and cured between the fibers of the core material It is equipped with a base material which becomes a mixture of these. It is preferable to use 1 type, or 2 or more types of polyester, acryl, and polypropylene as chemical fiber.

Therefore, the term "cement" is broadly defined as an inorganic substance that exhibits curability when it is immersed in water. According to such a definition, the term "cement" includes coal or gypsum in addition to the so-called cement which is centered on portland cement. In the present specification, coal and gypsum are used without being included in "cement".

As a core material, a part of chemical fibers are fused and entangled with each other in three dimensions, so that the composite material is reinforced with mechanical strength, in particular tensile strength, by the inter-entanglement between the fibers of the core material.

The manufacturing method of the present invention is a method for producing such a concrete composite material, which is one or two or more of polyester, acrylic and polypropylene, the chemical fiber having a lower melting point in the chemical fiber, which is the main material of the core material To form a core material with a solid surface by molding into a plate-like felt at a temperature higher than the melting point of the chemical fiber of the electrical low melting point side and lower than the melting point of the chemical fiber of the main material; And a step of impregnating the slurry formed by adding water to gypsum, coal or a mixture of two or more thereof to the core material to harden.

In the process of forming the core material, the chemical fiber, which is the main material of the core material, is mixed with the low melting point chemical fiber at a ratio of 20 to 50%, and the hot air at a temperature at which the low temperature melting point chemical fiber is at least partially melted between the chemical fibers. It is preferable to fuse the. The temperature of the hot air at this time is determined by the melting point of the chemical fiber as the material, but is 70 to 200 ° C.

Polyester fibers have a high melting point and a low melting point, so that polyesters having different melting points can be mixed with each other. Similarly for polypropylene fibers, polypropylene fibers with different melting points can be mixed with each other.

You can also mix different fibers together. For example, polyester fibers or polypropylene fibers having a lower melting point may be mixed with acrylic fibers, or polypropylene fibers having a lower melting point may be mixed with the polyester fibers.

In this way, fibers having different melting points are mixed with each other to melt at least a part of the chemical fibers on the low melting point side to fuse the fibers to form each other, which is called a solid surface.

Since the core is composed of a solid surface, the core can itself have a shape. For this reason, if the shape of a core material is made into the predetermined shape according to a use, it can be hardened by impregnating the slurry of a base material, and the concrete composite material which has a shape similar to a final product or it can be manufactured. However, in the step of impregnating the core material slurry to harden the core material, a slightly larger thickness or area may be produced, cut and processed into a predetermined dimension or shape according to the application.

EXAMPLE

Example 1

The polypropylene fiber having a lower melting point was mixed with the polyester fiber by 30%, and hot air at 120 ° C. was formed into a felt to form a core material having a solid surface.

The manufacturing method of a solid surface is the same also in a following example. The core material formed in this example is shown in Table 1.

Thickness of core material Density per square meter 5 mm 300 g500 g 10 mm 500 g 1 kg 20 mm 1 kg1.5 kg 30 mm 1.5 kg2 kg 50 mm 2 kg3 kg

Density is expressed in weight per m 2.

As a slurry to be impregnated with the core material, water was added and stirred at a ratio of 1 liter, 1.5 liter, and 2 liter, respectively, to 1 liter of powder in which Portland cement and gypsum were mixed at a ratio of 50%.

These slurries were impregnated into the respective core materials shown in Table 1, and left to air to cure.

(Example 2)

In the same manner as in Example 1, polypropylene fibers having a lower melting point were mixed with polyester fibers, and hot air was formed to form a felt to form a core material having a solid surface. The formed core material is shown in Table 2.

Thickness of core material Density per square meter 5 mm 300 g 10 mm 500 g 20 mm 1.5 kg 30 mm 2 kg

As a slurry to be impregnated with the core material, water was added and stirred at a ratio of 1 liter, 1.5 liter, and 2 liters per 1 liter of 100% gypsum powder, respectively. These slurries were impregnated to each of the core materials shown in Table 2, and left to stand in the air to cure.

(Example 3)

The core material used was shown in Table 2. As a slurry to be impregnated with the core material, water was added and stirred at a ratio of 1 liter, 1.5 liter, and 2 liters to 1 liter of 100% of Portland cement, respectively. These slurries were impregnated into each of the core materials shown in Table 2, and left to cure in the air.

(Example 4)

The core material which sandwiched the lath gold mesh for a building between two floors was made. The composition of the core is shown in Table 3.

Composition of Heartwood Surface density (per m²) 10 mm + gold mesh + 10 mm 500 g 10 mm + gold mesh + 20 mm 1 kg 20 mm + gold mesh + 20 mm 2 kg

In the column of the structure of the core material, for example, "10 mm + gold mesh + 20 mm" means that a lath gold mesh was sandwiched between a 10 mm thick surface and a 20 mm thick surface. The density of is expressed by the weight per square meter of the density with respect to the surface of 30 mm (total thickness of the surface of thickness 10mm and the surface of thickness 20mm).

(Example 5)

In the process of forming the core material which becomes a solid surface, in the state which put the lath gold net for building into the middle part of the thickness direction, it hit the chemical fiber and shape | molded it and formed the core material. The composition of the core is shown in Table 4.

Composition of Heartwood Surface density (per m²) 20 mm + gold mesh 500 g 30 mm + gold mesh 1 kg 40mm + gold mesh 2 kg

In the column of the structure of a core material, "30 mm + gold mesh" means what was shape | molded so that the lath gold mesh might be embedded in the middle part of the thickness direction of the 30-mm-thick surface. The gold mesh was molded to be almost at the center of the thickness direction of the solid surface, but may be biased in any direction.

The core of Table 4 was impregnated with a slurry prepared by adding water to 1 liter of 100% of Portland Cement at a ratio of 1 liter, 1.5 liter, and 2 liter, respectively, and stirred to stand in the air to cure.

The concrete composites produced in these examples were impregnated with the base material and left in the air, and when one day had elapsed, the concrete composite material was dried white and used as the core material having a thickness of 5 mm, and the thickness was 20 mm. In using, the surroundings were dried a little white. The thickness of the core was 30 mm and 40 mm, leaving the color of the cement still.

After 2 days, even the thick ones became white and dried. After 1 week elapsed, it dried and hardened also in the thing of thickness 50mm.

It is easy to impregnate the core as a slurry, and the mechanical strength of the finished concrete composite is also high in the case of the mixture of portland cement and gypsum, in the case of 100% gypsum, and in the case of 100% portland cement, It was a slurry made by adding 1.5 liters of water to 1 liter of powder. Slurries with a water ratio smaller than 1 liter are difficult to impregnate to the core of the core. On the contrary, the slurry having a water ratio of more than 2 liters is easy to impregnate the core material, but the filling rate of the base material of the finished concrete composite is low, and the mechanical strength is weak.

The slurry of 100% gypsum cured faster than the slurry of 100% Portland cement.

The core material with the gold screen for construction in the middle of the thickness direction of the surface, or the core material with the gold screen sandwiched between the two surfaces, added the mechanical strength of the gold screen to the tensile strength caused by the fiber of the cotton, and a more durable composite material. It became.

In particular, the core of Example 5 formed by inserting a gold mesh in the middle of the thickness direction in the process of forming a core made of a solid surface is intertwined between the chemical fibers of both sides sandwiching the gold mesh between the mesh and the fiber to integrate Because of this, it can be made of more durable concrete composite material.

In the concrete composite of Example 1, which was prepared using a slurry made by adding water at a ratio of 1.5 liters to 1 liter of powder mixed with portland cement and gypsum at a rate of 50%, the core surface of the core was approximately 40%. Occupied a volume. In other words, the cement and the gypsum of the base material occupy about 60% of the concrete composite material in volume, so that the cement and the gypsum are significantly lighter than the conventional plate of 100%.

As the material of the core material, regenerated products of chemical fibers such as polyester, acryl and polypropylene may be used. As the material of the base material, a piece of concrete may be pulverized into a powder and mixed with cement. By using such recycled products, the manufacturing cost can be lowered.

The concrete composite material of the present invention is to cure by filling a base material consisting of cement, gypsum, coal or a mixture of two or more of them between the fibers of the felt core material fused to a part of the three-dimensional intertwined chemical fibers, Inter-entanglement between the fibers of the core leads to concrete composites with mechanical strength, especially tensile strength.

In addition, the core material having a smaller specific gravity as compared to the cement of the base material occupies several ten percent of the volume, thereby reducing the specific gravity of the finished concrete composite material, resulting in a lightweight building material.

This concrete composite can be nailed and can be cut with a saw for woodworking if the gold mesh is removed. Therefore, it can be used for a wide range of purposes including building materials.

Although the invention has been described in detail only with respect to the described embodiments, it will be apparent to those skilled in the art that various changes or modifications can be made within the spirit and scope of the invention, and such changes or modifications are consequent to the appended claims. You will have to belong to the range.

Claims (6)

It is characterized by comprising a felt core material fused and intertwined three-dimensionally between chemical fibers, and a base material comprising cement, gypsum, coal, or a mixture of two or more thereof, which is filled and cured between the fibers of the core material. Concrete composite material. The composite material according to claim 1, wherein the electrochemical fiber is one or two or more of polyester, acryl and polypropylene. The concrete composite material according to claim 1 or 2, wherein a gold screen is embedded or sandwiched in an intermediate portion in the thickness direction of the felt-like core material. One or two or more of polyester, acryl, and polypropylene, and mixed with chemical fibers having a lower melting point than chemical fibers, the main material of the core material, and higher than the melting point of the chemical fiber on the electric low melting point side A step of forming a core material which becomes a solid surface by forming hot plate at a temperature lower than the melting point of the chemical fiber as a material and forming a sheet-like felt; A method for producing a concrete composite material, comprising the step of impregnating an electric core material with a slurry formed by adding water to cement, gypsum, coal or a mixture of two or more thereof. The process of forming a core material as a solid surface is characterized in that a gold mesh is sandwiched between intermediate portions in the thickness direction in a state in which chemical fibers are mixed, and then formed into a felt shape by hitting hot air in the state. Method for manufacturing concrete composite material. The method for producing a concrete composite material according to claim 4, wherein the electric slurry is impregnated in the core material in a state in which a gold mesh is sandwiched between two core materials.